Process for forming an airbag

Abstract

An airbag textile containing a woven textile having an inner side and an outer side, a primer layer on the outer side of the textile and a gas barrier layer on the primer layer. The primer layer contains a first thermoplastic polymer and has a surface roughness and a plurality of holes extending at least partially through the thickness of the primer layer. The gas barrier layer contains a second thermoplastic polymer and at least partially fills in the surface roughness and holes of the primer layer.

What is claimed is: 
     
       1. A process for forming an airbag textile comprising the steps, in order:
 obtaining a woven textile having an inner side and an outer side, wherein the one-piece woven textile substrate comprises a plurality of yarns, the yarns comprising polyester or polyamide fibers having a linear density of about 110 dtex or greater, and wherein the textile substrate has a cover factor less than 2000; 
 forming a foamed coating dispersion comprising a first thermoplastic and air, wherein the foamed coating dispersion comprises at least 50% by volume air; 
 coating the foamed coating dispersion at least a portion of the outer side of the woven textile forming a coated side and an uncoated side; 
 collapsing and at least partially drying the foamed coating dispersion forming a primer layer on the one side of the woven textile, wherein the primer layer has a surface roughness and a plurality of holes extending at least partially through the thickness of the primer layer, wherein the primer layer has a first thickness, and wherein the inner side of the textile substrate is essentially free of the first thermoplastic polymer; 
 coating a second thermoplastic polymer onto the primer layer, wherein the second thermoplastic at least partially fills in the surface roughness and holes of the primer layer; 
 drying the coating of the second thermoplastic polymer forming a gas barrier layer, wherein the gas barrier layer has a second thickness, wherein the second thickness is greater than the first thickness, and wherein the inner side of the textile substrate is essentially free of the second thermoplastic polymer. 
 
     
     
       2. The process of  claim 1 , wherein the foamed coating dispersion does not contain a chemical foaming agent. 
     
     
       3. The process of  claim 1 , wherein coating the foamed coating dispersion onto the one side of the woven textile comprises essentially none of the foamed coating passing completely through the woven textile onto the inner side of the woven textile. 
     
     
       4. The process of  claim 1 , foamed coating dispersion comprises at least 66% by volume air. 
     
     
       5. The process of  claim 1 , wherein the first thermoplastic polymer and the second thermoplastic polymer is the same thermoplastic polymer. 
     
     
       6. The process of  claim 1 , wherein the first thermoplastic polymer is a thermoplastic polymer selected from the group consisting of polyurethane, polyacrylate, acrylic co-polymer, and polyurethane-polyacrylate hybrid, acrylic, vinyl acetate, vinyl chloride, vinyl alcohol, urethane, styrene butadiene, acrylonitrile, ethylene vinyl acetate, and ethylene vinyl chloride, vinylidene chloride, polyvinyl chloride, Polyvinyl butyral, silicone, and hybrid resins. 
     
     
       7. The process of  claim 1 , wherein the second thermoplastic polymer is a thermoplastic polymer selected from the group consisting of polyurethane, polyacrylate, acrylic co-polymer, polyurethane-polyacrylate hybrid, acrylic, vinyl acetate, vinyl chloride, vinyl alcohol, urethane, styrene butadiene, acrylonitrile, ethylene vinyl acetate, and ethylene vinyl chloride, vinylidene chloride, polyvinyl chloride, Polyvinyl butyral, silicone, and hybrid resins. 
     
     
       8. The process of  claim 1 , wherein the second thermoplastic polymer on top of the primer layer is also foamed prior to application, collapsing at least partially during drying.